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Planning

We present an innovative approach to casting process planning based on case-based reasoning. Process planning involves deciding the methods, materials and machines for various steps in manufacturing. It is an important activity that affects product cost and quality, and requires experience. Such experience can be stored using a knowledge management system, then retrieved and modified for a new casting that is similar to a previous one (generative process planning). For entirely new castings, process plans are generated interactively by selecting the most appropriate options from a library, and become part of the case-base.

Design

A concept can be defined as a model or an idea, gradually developed on the basis of various studies, practical examples and nature of desired output. With a vision, that the proposed idea will be implemented and will achieve the desired target within the given timeframe. Concept development helps in analyzing and evaluating technologies to form the basic structure to some extent. A concept can be represented in the form of flowchart, block diagrams, textual figures. However, the supporting details to model the concept should be realistic so that the procedure of the concept is ensured.

Manufacturing

Casting manufacturing is a process in which liquefied material, such as molten metal, is poured into the cavity of a specially designed mold and allowed to harden. After solidification, the workpiece is removed from the die to undergo various finishing treatments or for use as a final product. Casting methods are typically used to create intricate solid shapes, and cast products are found in a wide range of applications, including automotive components, aerospace parts, electronics, mechanical devices, and construction supplies.

Methods of Inspection

In the casting process, first few castings will be inspected dimensionally and the pattern is qualified afterward, only a few random inspection will be done. Every casting must be inspected for finding out the defects in the casting process.
Visual Inspection
Hydrostatic Pressure Test
Magnetic Particle Inspection
Radiographic Examination
Ultrasonic inspection
Dye Penetrant Inspection
Coin Testing